Name: Machine Tool Technology ( )
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1 Name: Machine Tool Technology ( ) Directions: Evaluate the student by checking the appropriate number to indicate the degree of competency. Rating Scale (0-6): 0 No Exposure no experience/knowledge in this area; program/course did not provide instruction in this area 1 Unsuccessful Attempt unable to meet knowledge or performance criteria and/or required significant assistance 2 Partially Demonstrated met some of the knowledge or performance criteria with or without minor assistance 3 Knowledge Demonstrated met knowledge criteria without assistance at least once 4 Performance Demonstrated met performance criteria without assistance at least once 5 Repetitively Demonstrated met performance and/or knowledge criteria without assistance on multiple occasions 6 Mastered successfully applied knowledge or skills in this area to solve related problems independently A. Appreciate and apply all personal and work place safety procedures 1. Demonstrate appropriate work place safety practices (e.g., hand tools, power tools, fluid power, electrical, and environmental hazards) 2. Adhere to state and federal environmental/regulatory requirements/codes (e.g., OSHA and EPA) 3. Recognize when first aid is needed for occupational injuries and follow proper procedures 4. Identify types, purposes, and the operation of fire extinguishers and suppression resources 5. List machine shop safety rules and regulations B. Perform machine tool related mathematical calculations 1. Convert common fraction to decimal fraction and vice versa 2. Calculate measurement of right triangles 3. Determine tap drill size with formula and charts 4. Convert customary measurements to metric and vice versa 5. Use calculator to perform mathematical operations 6. Verify the accuracy of calculations derived with a calculator 7. Calculate amount of stock required 8. Calculate part and feature dimensions and locations 9. Convert revolutions per minute (rpm) to surface feet per minute (sfpm) 10. Calculate feeds and speeds 11. Determine tapers for machine set-up per formulas and charts 12. Determine sine bar set-up with formulas and charts 13. Perform angular and simple indexing calculations Machine Tool Technology Competency Profile (6/04) 1
2 C. Measure machined parts using industry recognized instruments 1. Measure using direct-reading instruments (e.g., scales, protractors, and precision levels) 2. Measure using transfer instruments (e.g., plain inside and outside calipers, telescoping gages, adjustable hole gages, and adjustable parallels) 3. Measure using precision measuring instruments (e.g., micrometers, gage blocks, verniers, dial indicators, and digital calipers) 4. Measure using surface plate instruments (e.g., height gages, angle plates, and sine bars and plates) 5. Measure using comparison instruments (e.g., radius gages, squares, cutter tooth gages and center gages) 6. Measure using other instruments (e.g., optical comparators) 7. Measure pitch diameters using thread wires 8. Measure using unconventional methods (e.g., digital readouts on milling machines) D. Interpret designs, drawings, and specifications 1. Interpret blueprints including common drafting symbols 2. Make a sketch from a finished workpiece 3. Calculate tolerances and allowances 4. Calculate missing dimensions 5. Use geometric dimensioning and tolerancing E. Plan work consistent with industry standards 1. Use Machinery s Handbook to plan work 2. Plan sequence of part layout based on blueprint information 3. Identify cutting tool types (e.g., steel and carbide) and their applications (e.g., mills and lathes) 4. Plan sequence of machining operations 5. Plan tooling sequences for machining operations 6. Calculate machining operation, setup, and tear down times Machine Tool Technology Competency Profile (6/04) 2
3 F. Inspect machined parts using industry standard tools/equipment 1. Inspect part using appropriate measuring instruments (e.g., scales, micrometers, verniers, and protractors) 2. Inspect part using surface plate instruments (e.g., indicators, height gages, angle plates, height-transfer gages, and sine bars and plates) 3. Inspect part using optical comparator 4. Inspect part using CMM (coordinate measuring machine) G. Collect and analyze quality control data 1. Follow a quality plan 2. Participate in capability study 3. Analyze the performance of a single-part production process 4. Analyze the performance of a production process H. Layout and fabricate bench work consistent with industry and safety standards 1. Cut materials with hand hack saw 2. Mark locations with prick and center punches 3. Locate holes with transfer screws and transfer punches 4. Bench file/deburr workpiece 5. Cut threads with die 6. Cut threads with hand tap 7. Ream holes with hand reamer 8. True and dress grinding wheels on pedestal/bench grinder 9. Grind and shape tools on pedestal/bench grinder 10. Use abrasives/whetting/polishing/lapping 11. Grind using appropriate hand grinder 12. Remove damaged screws 13. Remove broken drills and taps 14. Remove and install dowel pins 15. Install a thread insert Machine Tool Technology Competency Profile (6/04) 3
4 16. Straighten workpiece on arbor press 17. Assemble and disassemble workpiece with arbor press 18. Broach workpiece with broaching tool 19. Assemble and disassemble precision parts I. Describe and conduct material sciences procedures 1. Identify types of metals and related materials 2. List properties that affect machinability 3. Correlate types of materials to their properties 4. List major cutting tool variables 5. Perform heat treatment process 6. Test workpiece for hardness with and without hardness tester 7. Interpret time-temperature-transformation diagrams 8. Identify the effect of heat treatment on materials J. Operate power saws consistent with industry and safety standards 1. Perform power saw care and maintenance 2. Select blade type for sawing operations and materials 3. Cut and weld band saw blades 4. Select and set speeds and feeds on power saw 5. Cut material to length with power saw 6. Select and apply cutting fluids 7. Contour saw to scribed line 8. Saw internal contours with band saw K. Operate drill presses consistent with industry and safety standards 1. Perform drill press care and maintenance 2. Set up and clamp workpiece to drill press table Machine Tool Technology Competency Profile (6/04) 4
5 3. Select drill type based on job requirements 4. Determine cutting tool variables prior to use 5. Set up drill press according to calculated feeds and speeds 6. Select and apply cutting fluids 7. Drill holes to specification using manual and automatic feed 8. Countersink hole to specifications 9. Counterbore hole to specifications 10. Spotface to specific dimensions 11. Mount workpiece on V-blocks 12. Power ream hole to size 13. Use drill jigs and bushings 14. Hand tap hole using drill press 15. Tap hole with tapping attachments 16. Perform taper reaming and subsequent pipe tapping 17. Sharpen drills at a pedestal grinder or with grinding attachments and specialized grinders 18. Set up radial drill press L. Operate lathes consistent with industry and safety standards 1. Perform lathe care and maintenance 2. Align lathe centers using test bar and dial indicators 3. Select cutting tool based on job requirements 4. Calculate feeds and speeds for lathe set-up 5. Free-hand grind turning and facing tools 6. Select and apply cutting fluids 7. Operate lathe controls 8. Face workpiece and center drill 9. Set up tooling 10. Turn workpiece between centers 11. Indicate workpiece in four-jaw chuck Machine Tool Technology Competency Profile (6/04) 5
6 12. Drill, ream, bore, and countersink holes 13. Counterbore holes 14. Knurl parts 15. Free-hand grind 60-degree threading tool 16. Chase external/internal threads 17. Chase metric threads 18. Cut multiple lead threads 19. Cut Acme threads 20. Use compound rest to cut short external/internal tapered surfaces 21. Cut tapers by offset tailstock 22. Cut external tapered surface with taper attachment 23. Cut internal tapered surface with taper attachment 24. Align workpiece on faceplate 25. Perform lathe filing 26. Polish workpiece 27. Turn or thread long workpieces using follower and steady rest 28. Use form tooling 29. Use mandrel M. Operate milling machines consistent with industry and safety standards 1. Perform care and maintenance of milling machine 2. Tram (align) mill head 3. Select milling machine attachments according to job requirements 4. Align workpiece mounted on machine table 5. Calculate feeds and speeds and set up mill accordingly 6. Select and apply cutting fluids 7. Select cutting tool based on job requirements 8. Square up workpiece in milling vise using face mill 9. Mill workpiece with end mill Machine Tool Technology Competency Profile (6/04) 6
7 10. Locate work with edge finder 11. Drill holes with milling machine 12. Ream holes 13. Bore holes with milling machine 14. Use form cutter to mill workpiece 15. Machine workpiece mounted on V-blocks 16. Machine external straight keyway 17. Machine woodruff keyway 18. Mill simple and compound angles 19. Mill an external radius with rotary table 20. Mill an internal radius with rotary table 21. Mill workpiece using simple indexing operation 22. Use digital readout 23. Machine workpiece by straddle milling 24. Perform gang milling N. Operate grinders consistent with industry and safety standards 1. Perform grinder care and maintenance 2. Select and apply cutting fluids 3. Inspect and ring-test grinding wheel 4. Balance grinding wheel 5. Select and mount grinding wheel 6. True and dress machine tool grinding wheel 7. Grind workpiece on magnetic chuck using power feed 8. Square up workpiece on surface grinder 9. Indicate workpiece to be ground 10. Dress form on grinding wheel 11. Grind angular surfaces 12. Grind straight and tapered surfaces between centers using cylindrical grinding Machine Tool Technology Competency Profile (6/04) 7
8 O. Fabricate and resurface cutting tools consistent with industry and safety standards 1. Perform care and maintenance of tool-and-cutter grinder 2. Inspect and ring-test grinding wheels 3. Select and mount grinding wheel 4. True and dress grinding wheel 5. Set up machine 6. Sharpen cutters on tool-and-cutter grinders P. Operate and maintain computerized numerical control (CNC) machines consistent with industry and safety standards 1. Perform machine care and maintenance 2. Calculate coordinates and dimensions needed for CNC program 3. Write program for CNC machine 4. Set up a CNC machine 5. Machine workpiece with CNC machine Q. Operate electric discharge machines (EDM) consistent with industry and safety standards 1. Describe the electric discharge machine theory 2. Operate a wire electric discharge machine 3. Operate a plunge electric discharge machine 4. Operate a two-axis electric discharge machine R. Demonstrate leadership skills in the classroom, industry, and society 1. Demonstrate an understanding of SkillsUSA, its structure, and activities 2. Demonstrate an understanding of one s personal values 3. Perform tasks related to effective personal management skills 4. Demonstrate interpersonal skills Machine Tool Technology Competency Profile (6/04) 8
9 5. Demonstrate etiquette and courtesy 6. Demonstrate effectiveness in oral and written communication 7. Develop and maintain a code of professional ethics 8. Maintain an appropriate professional appearance 9. Perform basic tasks related to securing and terminating employment 10. Perform basic parliamentary procedures in a group meeting S. Explain and demonstrate skills in a specialization area identified by the instructor Machine Tool Technology Competency Profile (6/04) 9
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